PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CYLINDER HEAD VALVE ROTATOR ON CERTAIN G3516 AND G3520 GAS ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CYLINDER HEAD VALVE ROTATOR ON CERTAIN G3516 AND G3520 GAS ENGINES

Usage:

SEBE9139-01

April 20, 2005
(Revised June 2005)
U-115
A-85
D-96
O-101

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CYLINDER HEAD VALVE ROTATOR ON CERTAIN G3516 AND G3520 GAS ENGINES
1121		PI30777

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30777" as the Part number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI30777" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

NOTE: This Revised Service Letter replaces the April 20, 2005 Service Letter. Changes have been made to the Affected Product.

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COMPLETION DATE	TERMINATION DATE
October 31, 2005	April 30, 2006

PROBLEM

The cylinder head valve rotator needs to be inspected on certain G3520 and G3516 Generators Sets. Due to a design tolerance stack up problem the cylinder head valve rotator could interfere with the valve bridge assembly. This could cause the bridge to contact the valve rotator, damaging both and leading to possible valve failure. The engines need to be inspected, and adjusted if necessary.

A program PI30680 was issued June 2004 to complete the same inspection and repair but this has been determined not reliable due to parts wear predictions were under estimated. The same inspection and repair method is still being requested with additional material being removed.

AFFECTED PRODUCT

****Group 1****

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Model	Identification Number
G3516	TJB1-104 TJC1-819
G3516E	SLY1-107

****Group 2****

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Model

Identification Number

G3520C

CWW1-242

B9P1-214

MAD1-201

CWY1-216

HEA1-102

HEB1-104

HAT1-205

PARTS NEEDED

No parts are needed for this rework.

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	3.0	0	0	0	0
NOTE: This is a 3-hour job to inspect all cylinders. If rework is needed, an additional one hour per cylinder will be allowed. The number of cylinders that need to be reworked will vary. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)
(2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CYLINDER HEAD VALVE ROTATOR

MODELS INVOLVED - G3516 AND G3520 GAS ENGINES

Dear Caterpillar Product Owner:

The cylinder head valve rotator needs to be inspected and potentially reworked on the products listed below. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated April 20, 2005 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to April 20, 2005 Service Letter

Rework Procedure

Inspect and repair if necessary.

Using a .080-inch (or 2.0 mm) gage wire, place between the rotator and bridge. If the gage wire passes through the space the clearance is ok.
If the gage wire will not pass through the space:

Remove the rocker arm shaft assembly to remove the bridge assembly.

Using a die grinder, grind out a smooth radius on the underside of the bridge to provide clearance for the rotator.

Note; Grind Bridge enough to obtain .080-.090 inch(2.0-2.5mm)clearance between rotator and bridge.

Make sure the grind area is blended into the profile of the bridge so no rough edges are present, avoiding potential stress risers to initiate cracks.
Replace bridge and re inspect for allowed clearance. Confirm bridge adjustment is correct.
Reassemble rocker arm shaft and adjust valve lash to proper spec.